Kawasaki FD620D running poorly. Help?!

[gimmegreens336]

I meant to take the gas cap off last night to test this theory! Will try this tonight..

Next, the spark.. I had NAPA order a spark plug tester thingamabobber just a few minutes ago. Will be available in a few hours. Is this the same principle? What is the difference between using this little tester that lights up everytime it sparks? If there is no difference I could save myself $5.. lol

Thanks to everyone.. JohnF - RD - fmints - Spookum - and I'm sure I've forgot to mention others!

[plott hound]

plus 1 on the tank vent.had that happen to my lawn tractor and honda foreman.drove me crazy trying to figure it out.

Cool! Down to only one zillion things that can be wrong.

So, when it won't start, put it into neutral, pull a spark plug wire and hold your thumb on the end ... okay, just kidding on holding the thumb on the end - lay the wire next to the engine block, and have a helper crank it a bit for you. Check for spark. Works great at night.

Try to taking the gas cap off - could be that your tank vent is plugged. [edit] Do this when it dies and see if it suddenly gets better. Do this one first. It's really easy and doesn't require opening the hood. I'm voting this most likely of the things that I know.

I've heard of folks having intermittent problems with stuff floating around in the tank that plugs the fuel pickup for short periods.

[gimmegreens336]

I am getting stir crazy wanting to go home and work on this thing. I'm a glutton for knowledge and I freaking love working on this machine.. lol

There was no breather hose connected to the tubing right below the gas cap. There is a gas cap, then the 3"? black hose running to the tank itself. On the 3"? black hose there is the place for the breather tube. There was no breather tube there and I swear, if memory serves me, (which it normally doesn't, I've kinda burnt that away :P ) the little hole where a breather line used to be, the hole is plugged..? I will find out for sure when I get home but I swear that's what I remember. Would be too cool if that were the issue.

[gimmegreens336]

NAPA was fixing to close so I picked the spark plug tester up. Just says to connect the alligator clip to the probe to avoid grounding, then probe the spark plug boot. Should make it light up when the boot makes the spark plug fire?



So I need to run the Argo when I get home until it dies and won't restart. First take gas cap off to check for a vacuum in the gas tank, if all is well then use this probe on one spark plug at a time while trying to turn her over?

Thanks yall

[sparkola]

Sounds exactly like the problems I had about a year or so ago. The throttle handle was gunked up and after cleaning it and graphite lubing it i figured that would fix the problem. When I disconnected the throttle cable from the twist grip it was real smooth. When I hooked it back up, it would bind at wide open throttle. This caused me to check the linkages. They were binding if I recall correctly because it seems that after a time, the linkages tend to bend from repeated pulling. Its like Argo had the geometry messed up between the linkages and didn't do enough R&D on this during developement. I believe there was a recall of sorts for this problem and a new linkage setup was made available. I have the same year Conquest as you by the way. I thought about putting stronger springs on but just bent them back and lubed em up. Haven't had a prob with sticking throttle in 2 years. I had the same problem with breaking off tips for my rear cylinder spark plugs as well. Found an exhaust pushrod had jumped out of the rocker. Not good when a cylinder full of compressed fuel has no where for the spent exhaust gases to go. This is most definately caused by old fuel. My machine only had 45 hours on it when I bought it, but i think the fuel was from 97 LOL( This was 3 years ago) Always run high octane gas. It has less of a tendency to burn or detonate before ignition. It does not burn hotter. Not sure where the other guy came up with that. 4 oz of Marvel mystery oil to every tank of gas will keep the valves from sticking and the pushrods from popping out of place. As for your carb, you really need to sonic clean it to get the jet passageways fully cleaned of debris. I pulled my carb 3 times before I figured this out. The CJ14 plugs are correct for this engine. I would not use a screwdriver to check for TDC. Use something soft like a drinking straw. Sonic cleaners can be purchased from Harbor Freight Tools for about 60 bucks on sale.

[gimmegreens336]

Thanks for all the input Sparkola! The throttle needed a good sanding and some lube and it loosened up completely. I ordered a new set of springs anyway after bending the heck out of mine. That's weird that it burns up the rear plug. I took off the valve covers and the rods are in place, still need to adjust the rear lash I only did the front. I was going wrong by testing for TDC through the valve opening by the rods. I didn't know I was supposed to be sticking something down the spark plug hole. lol Yall gotta explain this stuff to newbs like me!


So I am busy trying to upload videos from last night. It ran better than the night before. Again, it would start and idle like a champ. Rev like a champ. Took her out to ride until she failed to check for a vacuum in the tank. No vacuum. Checked for spark, plenty of spark. Tried to fire her back up, and she did. (This is new, before it wouldn't fire after turning off) Rode her again till she failed. Checked for spark again, plenty of spark. Fired right back up again. Rode some more, started to turn off so I choked her and she stayed running. Let her choke for a sec, turned choke off and went for another ride. This happened time and time again. I could ride with 30% or less throttle forever, she runs for a few minutes under load then wants to turn off, I choke her to stay on, then ride again till it happens again.

This is a fuel problem?

Thinking of replacing the fuel pump just to rule out something crazy. It pumps a good steady flow but maybe it's shorting out like fmints said his buddies did? I don't know... It's SO CLOSE to running right. Just have to choke her to keep her alive when she tries to die under heavy load.

[gimmegreens336]

Does anyone use an iPhone to upload videos??? This is majorly aggravating. I just switched from an Android phone to this POS and I've had buyers remorse every since. The YouTube app in the app store doesn't have an upload option, (and has a 2.5/5 star rating) there is a button on the actual video for uploading to YouTube but it doesn't recognize my username (I tried at least a dozen times, enough to piss someone off) and I can sign on the YouTube site on the browser, but there is no option for uploading a video on there either.

Help?

[gimmegreens336]

This is unrelated to engine trouble!

My secondary clutch spins fast in neutral, wondering if that's normal. Also, the primary clutch spins real fast while in gear even when belt is not spinning. Is this normal?

Thanks!

Edit: I obviously found out how to upload videos, the problem now is that if I use email to upload videos then 55 seconds is max... The other three I wanted to upload from the ride were closer to 2 minutes so I need a better way to upload.

[gimmegreens336]

You don't have to watch this, but it shows a strong spark right after she died. I think my coils are ok.

[gimmegreens336]

Bought a new fuel pump. Will install tonight. I'm running out of options. I think it's fuel related. Next will be a new carb?

[plott hound]

Bought a new fuel pump. Will install tonight. I'm running out of options. I think it's fuel related. Next will be a new carb?

great prices on kawi engine parts at beiler engines.i bought a lot of goodies from them this year.

[JohnF]

... the primary clutch spins real fast while in gear even when belt is not spinning. Is this normal?

The primary clutch (or drive pulley) only spins when the engine is running. To stop it's spinning, turn the key off.

[rapidroy]

Bought a new fuel pump. Will install tonight. I'm running out of options. I think it's fuel related. Next will be a new carb?

Just a thought here to throw my two cents in with the rest. In the gas tank below the pick up tube is a small dimple, i believe it is a good place for water to collect along with other things that could clog the end of the tube and then fall out when you turn the key off. Wont cost anything to check for obstructions, though you might have to pull the tank to flush anything you find in there. If it is a bunch of water then iso propyl alcohol will remove it without pulling the tank. Good luck // RR

[gimmegreens336]

Installed the new pump, was just as loud as the old pump so I guess these things just hum?

Result: worse operation. lol

Anyway - to follow-up on rapidroy - You're talking about the little coffee cup sized dimple in the bottom of the tank that the line rests in? That would be a good place for trash to rest. I did empty and clean the tank when I started working on this. I also replaced all the fuel line except for the piece down in the tank. I'm gonna take it off tonight and see if it's obstructed. I was pissed after she acted worse so I didn't check anything at all. I didn't even check for fuel flow at the carb. I plan to work a little tonight with it. Will followup with results.

Thanks yall

[gimmegreens336]

Pump is pumping! Couldn't see any trash in the dimple in the bottom of the tank, blew out that little hose to be safe. Same problems. It's carburetor related. When you twist the throttle while it's idling you should visibly see fuel squirting down the throat of the carb, right? I don't see anything... Also, when it won't start at all, if I pour fuel down the throat of the carb she starts up for a sec, might smoke a little, then dies and coughs a little smoke out the carb. Carburetor is removed and disassembled again and I'm gonna blow her out for the final time. I still swear the bowl isn't filling up with fuel. When I loosen the drain screw there is less than 1oz of fuel that comes out. To me, that's an empty bowl. I want to order a new float assembly but then I wonder if I should just order a new carb?

That reminds me...

It looks like the carb, or my gasket, fits wrong? Check the pictures out. The gasket fits the carb but does not fit the top end correctly. It is the same shape as the old gasket that was installed, although the old gasket was not metal. Also, a small rip was in the gasket right below the tab on the gasket.





Hard to see, but the gasket doesn't fit the top end well. There are metal ledges that stick out around all sides. I was wondering about the seal.



The metal gasket left a little metal residue around the post. What causes this? Heat?





Anyway, I ordered two new gaskets last week, should be here soon.

Thanks for everyone's help!